US5834732A - Apparatus for controlling consumable electrode type pulsed arc welding power source - Google Patents

Apparatus for controlling consumable electrode type pulsed arc welding power source Download PDF

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US5834732A
US5834732A US08/566,546 US56654695A US5834732A US 5834732 A US5834732 A US 5834732A US 56654695 A US56654695 A US 56654695A US 5834732 A US5834732 A US 5834732A
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signal
period
voltage
setting circuit
circuit
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Tetsu Innami
Wang Jingbo
Hideki Ihara
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Panasonic Holdings Corp
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Matsushita Electric Industrial Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
    • B23K9/091—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits

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  • the present invention relates to an output control apparatus of a consumable electrode type pulsed arc welder which uses a shielding gas of carbon dioxide gas as its main composition.
  • a shielding gas of an inert gas e.g., argon gas as its main composition.
  • a peak current larger than a value of critical current above which a spray transfer is possible and a base current lower than the critical current for maintaining an arc are fed or passed alternately at a frequency corresponding to a wire feeding speed.
  • the spray transfer can be made with a lower average current than DC welding method, and the droplet transfer is made during the period of base current in such a state that a least arc force act on the droplet. Consequently, spatter could be reduced largely.
  • the above-mentioned pulsed arc welding method has a restriction in choosing a shielding gas composition, because of the fact that, the spatter reducing effect becomes weak when the content ratio of carbon dioxide in a shielding gas exceeds 30%. Therefore, a large amount of argon gas is consumed, and accordingly the cost of the shielding gas has been a main cause of high running cost of the pulsed arc welding method.
  • the present invention purposes to prevent spatter generation, by performing the welding in a shielding gas including carbon dioxide gas as its main composition.
  • the spatter formation is prevented by lowering the power output responding to the detachment detection signal that is issued in synchronism with the droplet detachment.
  • the output controller for a consumable electrode type pulsed arc welder in accordance with the present invention comprises a voltage detector for detecting the welding voltage, a comparator for performing a comparison arithmetic calculation between a detected voltage and a reference voltage from a voltage setting circuit to issue a detection signal when the detected voltage exceeds the reference voltage, and an output adjustor for reducing the welder output to a lower level lower than a peak current.
  • a further feature of the above-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the preceding feature, the comparator receives as inputs, an output signal from the initial voltage memory for memorizing a voltage value at the starting time of peak current conduction memorized by the signal from the voltage detector, a detected signal from the voltage detector, and a setting signal from the voltage setting circuit, and the comparator issues an output when a difference between the detected voltage from the voltage detector and the initial voltage from the initial voltage memory exceeds a set voltage set by the voltage setting circuit.
  • a further feature of the output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the first-mentioned feature, the comparator issues its detection signal when a differential value from a differentiator for detecting a variation rate of the detected voltage from the voltage detector exceeds a value set by a differential value setting circuit.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the preceding feature, a period setting circuit is provided for setting a voltage rising period at the time of transfer from short-circuit to arc by receiving an output from a short-circuit detector for discriminating the short-circuit and the arc from a comparison between a detected output from the voltage detector and a set value from a reference value setting circuit, and when a time lapse is less than a set period set by the period setting circuit, the detection signal from the comparator is canceled.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the first-mentioned feature, the comparator receives as its inputs, a detected voltage value from the voltage detector and a detected current value from the current detector for detecting the welding current, and performs a comparison arithmetic calculation between a detected resistance value from a resistance value operator for making an arithmetic operation for obtaining a detected resistance value and a reference resistance value from a resistance value setting circuit, and then issues a detection signal when the detected resistance value exceeds the reference resistance value.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the first-mentioned feature, the comparator receives as inputs, a detected voltage value from the voltage detector and a detected current value from the current detector for detecting the welding current, and receives an output signal from a resistance value operator for making an arithmetic operation for obtaining a detected resistance value, an output signal from an initial resistance value memory for memorizing a resistance value at the time of pulse conduction starting, and a set signal set by the resistance value setting circuit, and issues a detection signal when a difference between a detected resistance value of the resistance value operator and an initial resistance value from the initial resistance value memory exceeds a reference resistance value from the resistance value setting circuit.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the first-mentioned feature, the comparator receives as its inputs, a detected voltage value from the voltage detector and a detected current value from the current detector for detecting the welding current, and issues its detection signal when a differential value from a differentiator for detecting a variation rate of the resistance value signal from the resistance value operator for making an arithmetic operation for obtaining a detected resistance value exceeds a set value set by a differential value setting circuit.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the preceding feature, a period setting circuit is provided for setting a voltage rising period at the time of transfer from short-circuit to arc by receiving an output from a short-circuit detector for discriminating the short-circuit and the arc from a comparison between a detected output from the voltage detector and a set value from a reference value setting circuit, and when a time lapse is less than a set period set by the period setting circuit, the detection signal from the comparator is canceled.
  • the output can be suppressed to the low level of I r . Therefore, the arc force acting on the droplet during the transfer to the droplet can be suppressed. Thereby, the spatter yield can be reduced.
  • the output controller for the consumable electrode type pulsed arc welder in accordance with the present invention comprises a voltage detector for detecting the welding voltage, a comparator which performs a comparison arithmetic calculation between a detected voltage from the voltage detector and a reference voltage from a voltage setting circuit and issues a detection signal when the detected voltage exceeds the reference voltage, a lowering period setting circuit, a lowered current setting circuit, and a pulse waveform generator to which setting signals from the above-mentioned lowering period setting circuit, from the above-mentioned lowered current setting circuit, from the pulse period setting circuit, from the base current setting circuit, and from the peak current setting circuit, and to which also the detected signal of the above-mentioned comparator are all inputted, and issues a pulse so that the peak current level is lowered, with taking the detected signal from the above-mentioned comparator as a starting time point, to the level of the lowered current which is lower than the peak current and set by the lowered current setting circuit during a lowering period which
  • the spatter yield can be reduced.
  • a further feature of the output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the preceding feature, the pulse generator receives an output signal of a lowering period adjusting circuit having its inputs of a setting signal from the lowering period setting circuit and a detected voltage from the voltage detector, and those detected signals from the lowered current setting circuit, from the pulse period setting circuit, from the base current setting circuit, and from the peak current setting circuit, and also receives all the detected signal of the above-mentioned comparator, and then issues a pulse so that the peak current level is lowered, with taking the detected signal from the above-mentioned comparator as a starting time point, to the level of the lowered current which is lower than the peak current and set by the lowered current setting circuit during lowering period t M +lowering adjusting period ⁇ t M , which was adjusted by a lowering period adjusting circuit and lasts at least until a time point of occurrence of perfect transfer from the droplet to the weld pool.
  • the droplet can be transferred completely to a weld pool. Thereby, the spatter yield can be reduced.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder is that, besides the afore-mentioned feature, the pulse waveform generator receives detected signals from the lowering period setting circuit, from a lowered current setting circuit, from a period extension setting circuit, from the pulse period setting circuit, from the base current setting circuit, and from the peak current setting circuit, and also the detected signal of the above-mentioned comparator, and then issues a pulse so that the peak current level is lowered, with taking the detected signal from the above-mentioned comparator as a starting time point, to the level of the lowered current I r , which is lower than the peak current I p and set by the lowered current setting circuit during a lowering period t M which was set by the above-mentioned lowering period setting circuit and lasts at least until a time point of occurrence of perfect transfer from the droplet to the weld pool, and the pulse period in which the droplet detachment is
  • the spatter is reduced and possibility of undesirable breaking of the arc is avoided, and further the welding voltage can be made uniform. As a result of these, a stable welding can be obtained.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the aforementioned feature, the pulse waveform generator receives an output signal of a lowering period adjusting circuit having its inputs of a setting signal from the lowering period setting circuit and of a detected voltage from the voltage detector, and those detected signals from the lowered current setting circuit, from the period extension setting circuit, from the pulse period setting circuit, from the base current setting circuit, and from the peak current setting circuit, and also receives the detected signal of the above-mentioned comparator, and then issues a pulse so that the peak current level is lowered, with taking the detected signal from the above-mentioned comparator as a starting time point, to the level of the lowered current I r which is lower than the peak current I p and set by the lowered current setting circuit during lowering period t M +lowering adjusted period ⁇ t M , which was adjusted by the above-mentioned lowering period adjusting circuit and lasts at
  • the droplet can be transferred completely to the weld pool even when the presence of the welding voltage variation.
  • the spatter yield can be reduced, and also, the welding voltage can be stabilized, thus giving a stable welding capability.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the afore-mentioned feature, a pulse waveform generator receives an output signal of a lowering period adjusting circuit having its inputs of a setting signal from the lowering period setting circuit and a detected signal from the voltage detector, and an output signal of an extension adjusting circuit having its inputs of a setting signal from the period extension setting circuit and of a detected voltage from the voltage detector, and those detected signals from the lowered current setting circuit, from the pulse period setting circuit, from the base current setting circuit, and from the peak current setting circuit, and also receives the detected signal of the above-mentioned comparator, and then issues a pulse so that the peak current level is lowered, with taking the detected signal from the above-mentioned comparator as a starting time point, to the level of the lowered current I r which is lower than the peak current I p and set by the lowered current setting circuit during lowering
  • the time period T M during which the peak current is lowered to the lowered current I r after detection of the droplet detachment from the welding wire tip and the time period T E wherein period of the pulse in which the droplet detachment was detected is extended, become t M + ⁇ t M and t E + ⁇ t E , respectively.
  • These time periods are those in which the lowering adjusting period ⁇ t m and the extension adjusting period ⁇ t E , which vary corresponding to the welding voltage value fed back during the welding operation, are added respectively to the lowering period t M and the extension period t E . Therefore, even when a variation in the welding voltage occur, the droplet can be transferred completely to the weld pool. Thereby, the spatter yield can be reduced, and also, the welding voltage can be stabilized, thus giving a stable welding capability.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the afore-mentioned feature, the lowering period adjusting circuit is a fuzzy inference operation circuit having its inputs of a setting signal from the lowering period setting circuit and a detected voltage from the voltage detector.
  • a further feature of the afore-mentioned output controller for the consumable electrode type pulsed arc welder of the invention is that, besides the afore-mentioned feature, the extension adjusting circuit is a fuzzy reasoning circuit having its inputs of a setting signal from the above-mentioned period extension setting circuit and a detected voltage from the voltage detector.
  • a droplet grown from melted wire tip is subject to arc force, surface tension, and gravitational force. Balance held among these forces is lost along with the growth of the droplet, thereby eventually making the droplet detachment out from the wire tip.
  • the conventional process is explained by using a schematic drawing of FIG. 2 wherein the process is illustrated making a correspondence between the process and the output voltage.
  • FIG. 2 (a) to (f) are drawings illustrating the state of the droplet on the tip of a wire. Therein temporal correspondence with the welding voltage waveform is shown by arrows.
  • the droplet 41 grows rapidly (FIG. b).
  • a constricted portion k is produced immediately below a solid part 40 of the wire ((c) of FIG. 2). This constricted portion k is extended with time.
  • the droplet escapes from the wire tip ((d) of FIG. 2).
  • an arc 42 becomes longer than before, since the pole moves from the bottom of the droplet to the tip part of the wire.
  • the arc length becomes further longer, being assisted also by such effect that a part g of the wire having a small heat capacity is melt directly by the arc. Since this increase of the arc length induces a voltage rise on the welding voltage, the welding voltage waveform rises rapidly on a course from the state shown in c of FIG. 2 to that shown in ((d) of FIG. 2). Thereafter, the wire starts melting again and a droplet is formed. However, because of the relation between the wire feeding speed and the melting amount, the arc length does not become short ((e) of FIG. 2).
  • the rise of voltage or resistance caused by the droplet detachment can be detected by a comparison detection using a comparison with respect to an absolute value or by an increment detection using an increment starting from the pulse initial time or by a rise-rate detection using a differential.
  • an detachment detection signal can be issued as an output in keeping the synchronism with the droplet detachment.
  • the welder output is lowered during a certain lowering period.
  • the consumable electrode type pulsed arc welding using a shielding gas including carbon dioxide gas as its main composition is carried out under the droplet transfer state, and there is a possibility that a short-circuiting takes place depending on the working condition.
  • this short-circuit recovery gives an erroneous detection signal. Therefore, there is a necessity of canceling such the differential signal at the time of short-circuiting recovery.
  • a fuzzy inference operation can be employed for the adjustment of the lowering period in which the welder output is lowered in accordance with the detection of occurrence of the droplet detachment.
  • a fuzzy predictor having a certain constant elongated period signal set by the elongated period setting means and a voltage signal detected by a voltage detection means as its input signal can be used.
  • FIG. 1 is a block diagram showing the constitution of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 1 of the present invention.
  • FIG. 2 is a schematic drawing of the prior art illustrating the relation between the state of the droplet and the state of the output voltage.
  • FIG. 3 is a waveform chart showing the relation between the output voltage/current and the detachment detection in the Example 1.
  • FIG. 4 is a block diagram showing the constitution the output control apparatus of the consumable electrode type pulsed arc welder in accordance with an Example 2 of the present invention.
  • FIG. 5 is a block diagram showing the constitution of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with the Example 3 of the present invention.
  • FIG. 6 is a block diagram showing the constitution of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 4 of the present invention.
  • FIG. 7 is a block diagram showing the constitution of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 5 of the present invention.
  • FIG. 8 is a block diagram showing the constitution of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 6 of the present invention.
  • FIG. 9 is a block diagram showing the constitution of the output adjusting circuit of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 7 of the present invention.
  • FIG. 10 is a schematic waveform chart showing one example of the welding current waveform in the Example 7 of the present invention.
  • FIG. 11 is a block diagram showing the constitution of the output adjusting circuit of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 8 of the present invention.
  • FIG. 12 is a block diagram showing the constitution of the output adjusting circuit of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 9 of the present invention.
  • FIG. 13 is a schematic waveform chart showing one example of the welding current waveform in the Example 9 of the present invention.
  • FIG. 14 is a block diagram showing the constitution of the output adjusting circuit of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 10 of the present invention.
  • FIG. 15 is a block diagram showing the constitution of the output adjusting circuit of the output control apparatus of a consumable electrode type pulsed arc welder in accordance with an Example 11 of the present invention.
  • FIG. 16 is a schematic waveform chart showing one example of the welding current waveform in the Example 11 of the present invention.
  • FIG. 1 is a drawing showing a first example of the present invention.
  • Periodic output trace waveform are formed by a pulse waveform generator 20 for defining a peak current I p , value of which is set by a peak current setting circuit 19 and duration or pulse period of which is set by a pulse period setting circuit 17, and also a base current I b , value of which is set by a base current setting circuit 18 and the duration or the pulse period is set by the same pulse period setting circuit 17.
  • the output current is controlled so as to be in agreement with the above-mentioned output trace waveform, and this output signal is inputted into an output control device 1.
  • the output thus controlled by the output control device 1 is voltage-transformed to a lower voltage by a transformer 2 and rectified into a DC current by a rectifier 3, and then smoothed by a reactor 4, and applied across an electrode 8 and a base metal 9.
  • a voltage detector 13 the welding voltage waveform is inputted into a comparator 14 as a detected voltage V O , and therein compared with a reference voltage V ref set by a voltage setting circuit 15.
  • FIG. 3 shows a relation among a detected voltage V O , a welding current, and the reference voltage V ref .
  • the voltage waveform becomes a different waveform from that of FIG. 2, because the output in that period is dropped to a lower level upon detection of the droplet detachment.
  • the reference voltage V ref takes a value set by the voltage setting circuit 15.
  • the comparator 14 issues a detachment detection signal at the time point A.
  • An output adjusting circuit 16 receives the above-mentioned detachment detection signal and issues a signal to the output controller 11.
  • the output controller 11 issues such a control signal I c as to make an output current from an output circuit 1234 to a lower level signal I r than the peak current I p , during the pulse period after the detachment detection signal (at the time point A) within the pulse period (which was set by the pulse period setting circuit 17).
  • the output current of the output circuit 1234 becomes such that, as shown by the lower curve of FIG. 3, the current I p is greater in the first half part of the pulse period, and then becomes to the lower level of I r after the droplet detachment detection time point A.
  • the arc force acting on the droplet after the detachment is weakened, and the occurrence of the spatter spray can be prevented.
  • FIG. 4 is a drawing showing a second example of the present invention.
  • an initial voltage memory 22 memorizes an input from a voltage detector 13 at a point of time which is after a constant time period counted from the starting of pulse conduction upon receiving the output of the pulse period setting circuit 17.
  • the above-mentioned constant time period starting from the pulse conduction start is determined by a response speed which is also determined by such as time constants of the power supply circuit, and the constant time period is normally set around 1 ms.
  • a voltage difference ⁇ V between a memorized voltage of the above-mentioned initial voltage memory 22 and the input voltage value of the voltage detector 13 is calculated.
  • a reference voltage V ref is inputted separately from the voltage setting circuit 15.
  • the comparator 21 issues the detachment detection signal. Operations thereafter are substantially the same with that of the first example described above. In this example, similarly to in the first example, it is possible to obtain the effect that the arc force acting on the droplet after the detachment is weakened and thereby the spatter spray is prevented.
  • FIG. 5 is a drawing showing a third example of the present invention.
  • a differentiator 23 differentiates the detected voltage from the voltage detector 13.
  • a differentiated value dV/dt thus derived is inputted into the comparator 14, where it is compared with a reference value V dr given from a differential value setting circuit 27.
  • the comparator 14 issues the detachment detection signal.
  • a short-circuit detector 25 compares the detected voltage given from the voltage detector 13 and with the input from the reference voltage setting circuit 24. The short-circuit detector 25 issues the arc state signal when the detected voltage is larger; and it issues the short-circuit state signal when the detected voltage is smaller.
  • a period setting circuit 26 receives a signal from the above-mentioned short-circuit detector 25 and counts a certain constant time period starting from the point of time when the short-circuit state transfers to the arc state.
  • the counted time period is determined by the response speed which is also determined by such as time constants of the power supply circuit; and it is normally around 1 ms.
  • the output adjusting circuit 28 receives input from the pulse period setting circuit 17 and cancels the detachment detection signal for a constant time period after a changing from the base current conduction to the pulse conduction.
  • This constant time period is determined by the response speed which is also determined by such as time constants of the power supply circuit and it is normally around 1 ms. The reason of carrying out cancellation using these two detachment detection signal system is for preventing erroneous detection.
  • the dual detachment detection signal system prevents those erroneous detection due to voltage rises at the time of transfer from the short-circuit state to the arc state, as well as, due to differential value rise at the time or caused by the voltage rise at the time of transfer from the basic conduction to the pulse conduction.
  • the output adjusting circuit 28 issues the signal to the output controller 11.
  • the output controller 11 issues such a signal I c as to make an output current from an output circuit 1234 to a lower level signal I r than the peak current I p , during the pulse period after the detachment detection signal (at the time point A) within the pulse period (which was set by the pulse period setting circuit 17). Operations thereafter are substantially the same as that of the afore-mentioned first example.
  • FIG. 6 is a drawing showing a fourth example of the present invention. Different from the afore-mentioned first to third examples (FIGS. 1, 3, and 5) in which the detachment detection has been made by the detected voltage detected by the voltage detector 13, in this fourth example of FIG. 6, the similar detachment detection is obtained by using a resistance signal.
  • a resistance value operator 29 calculates a resistance value from output current and output voltage values from a current detector 12 and a voltage detector 13, and thereby the result is issued to the comparator 14.
  • the comparator 14 compares an input resistance value from the resistance value operator 29 and a reference resistance value from a resistance value setting circuit 30.
  • the comparator 14 issues the droplet detachment detection signal to the output adjusting circuit 16 at a time point when the input resistance exceeds the reference resistance.
  • the comparator 14 by detecting the rise of the resistance value associated with the droplet detachment, similarly to in the first example, it is possible to obtain the effect that the arc force acting on the droplet after the detachment is weakened and thereby the spatter spray is prevented.
  • Working after the output adjusting circuit 16 are the same as that of the afore-mentioned first example.
  • FIG. 7 is a drawing showing a fifth example of the present invention.
  • the resistance value operator 29 calculates a resistance value from output current and output voltage values from a current detector 12 and a voltage detector 13, respectively; and the calculated result is issued to the comparator 21 and also to an initial resistance value memory 31.
  • the initial resistance value memory 31 further receives the output from the pulse period setting circuit 17 and memorizes an input from the resistance value operator 29 at a point of time after a constant time interval starting from the pulse conduction start.
  • a resistance value difference ⁇ R between the resistance value of the above-mentioned initial resistance value memory 31 and the input value to the resistance value operator 29 is calculated.
  • a reference resistance value R ref is inputted separately from the resistance value setting circuit 30.
  • the comparator 21 issues the detachment detection signal to the output adjusting circuit 16.
  • the comparator 21 issues the detachment detection signal to the output adjusting circuit 16.
  • FIG. 8 is a drawing showing a sixth example of the present invention.
  • the resistance value operator 29 calculates a resistance value from output current and output voltage values from a current detector 12 and a voltage detector 13, respectively and the calculated result is issued to a differentiator 23. Therefore the comparator 14 compares a differential value of the resistance value dR/dt with a reference value R dr of a differential value setting circuit 27, and issues the detachment detection signal at a point of time when dR/dt exceeds R dr . By performing such operation, similar effects to those of the afore-mentioned third example can be obtained. Operations after the output adjusting circuit 28 are the same as that of the aforementioned third example.
  • the setting value I r is a value for a low level output setting, and therefore it is also possible to use the setting value I b of the base current setting circuit 18 therefor.
  • FIG. 9 is a drawing showing a seventh example of the present invention and a concrete example of the output adjusting circuit 28 in those respective first to sixth examples.
  • the whole or general configuration is similar to those of the first to sixth examples and has the same function, and hence those aforementioned explanations and notations can be applied also in this example. Therefore redundant overlapping description is avoided here.
  • Those respective setting signals from a lowering period setting circuit 34, a lowered current setting circuit 35, the pulse period setting circuit 17, the base current setting circuit 18, and the peak current setting circuit 19 and also an output signal of the comparator 14 are all inputted into a pulse waveform generator 33.
  • the detected signal from the current detector 12 and the output signal from the above-mentioned pulse waveform generator 33 are inputted into an output controller 32.
  • the pulse waveform generator 33 issues to the output controller 32 a pulse signal of a waveform formed by a pulse period t p , a base period t b , a base current I b set by the base current setting circuit 18, and a peak current I p set by the peak current setting circuit 19.
  • the above-mentioned pulse waveform generator 33 issues to the output controller 32 a signal of lowered level current waveform.
  • the lowered level current signal is such that, only with regard to those pulses in which the droplet detachment is detected, at least for a lowering time period T M counted from the point of time of droplet's detachment to the completion of transfer of the droplet into the weld pool, the current is reduced to a lowered level circuit I r set by the lowered current setting circuit 35, which is no higher than the peak current I p .
  • the detected current from the current detector 12 and the pulse waveform signal from the above-mentioned pulse waveform generator 33 are inputted. Then the output is controlled in a manner that the above-mentioned detected current becomes to coincide with the above-mentioned pulse waveform.
  • the output of this output controller 32 is inputted into the output control device 1.
  • the level of the output current waveform becomes such that it is I p in the first half part of the pulse period, and then is lowered to the value of I r for a certain time period t M after the droplet detachment detection.
  • the arc force acting on the droplet after the droplet detachment is weakened so as to be able to prevent the spatter spray.
  • This lowering period t M is set by the lowering period setting circuit 34.
  • FIG. 10 shows an example of welding current waveforms which was obtained by the present example (Example 7).
  • the drawing shows such an example that the lowered current I r , which starts at the point of time of droplet detachment after the droplet detachment detection, is of a value between the peak current I p and the base current I b .
  • this lowered current I r it is desirable to set this lowered current I r to be the base current I b .
  • FIG. 11 is a drawing showing an example of the output adjusting circuit as an eighth example of the present invention.
  • the whole configuration of the output controller is similar to those of those first to sixth examples and has the same function, and therefore those aforementioned explanations and notations can be applied also in this example. Therefore redundant overlapping description is avoided here.
  • the lowering period setting circuit 34 which generates one of those input signals to the pulse waveform generator 33 of the output adjusting circuit in the above-mentioned seventh example, is replaced by a lowering period adjusting circuit 36.
  • the lowering period adjusting circuit 36 receives output signal of the lowered period setting signal of the lowering period setting circuit 34 and the output signal of the voltage detector 13 as its input signals, and adjusts the lowering time period.
  • the action of the circuit is explained below. Hereupon, overlapped explanations on the actions of those common parts with those of the above-mentioned seventh example are omitted.
  • a feedback signal of the welding voltage from the voltage detector 13 and the setting signal of the lowering period setting circuit 34 are inputted.
  • the lowering period t M set by the above-mentioned lowering period setting circuit 34 is issued without any adjustment from the above-mentioned lowering period control circuit 36.
  • the above-mentioned welding initial time period is set to be around 1 second.
  • the above-mentioned pulse waveform generator 33 issues to the output controller 32 a pulse signal of lowered level current waveform.
  • the lowered level current pulse signal is such that, only with regard to those pulses in which the droplet detachment is detected, at least for a lowering time period t M counted from the point of time of droplet's detachment to the completion of transfer of the droplet into the weld pool, added with the lowering adjustment period ⁇ t M , that is for the total time period t M + ⁇ t M , the current is reduced to a lowered level current I r set by the lowered current setting circuit 35; and the current I r is set by the lowered current setting circuit 35, and the current I r is no higher than the peak current I p .
  • the output current waveform becomes such that it has a level I p in the first half part of the pulse period and becomes a lower value of I r in the time period t M + ⁇ t M after the droplet detachment detection.
  • the arc force acting on the droplet after detachment is weakened, thereby enabling to prevent the spatter spray.
  • This lowering period t M + ⁇ t M is set by the lowering period adjusting circuit 36.
  • the above-mentioned lowering adjusted period ⁇ t M differs depending on ranges of the initial setting voltage, and boundaries between ranges of the initial setting voltage is complicated. Because of such reason, in the present invention, it is preferable to derive arithmetically the lowering time period T m +the lowering adjusted period ⁇ t M by the fuzzy inference operation.
  • FIG. 12 is a drawing showing an example of the output adjusting circuit in the ninth example of the present invention.
  • the whole or general configuration is similar to those of the first to sixth examples and has the same function. Therefore, those aforementioned explanations and notations can be applied also in this example. Therefore redundant overlapping description is avoided here.
  • a pulse waveform generator 37 is provided in place of the pulse waveform generator 33 of the aforementioned seventh example.
  • the same numerals are given and overlapping explanation thereon is omitted.
  • those respective setting signals from the period extension setting circuit 38, the lowering period setting circuit 34, the lowered current setting circuit 35, the pulse period setting circuit 17, the base current setting circuit 18, the peak current setting circuit 19 and also the output signal of the comparator 14 are all inputted into a pulse waveform generator 37.
  • the action of this circuit is explained below. Hereupon, explanation on the action of those parts common with that of the above-mentioned seventh example are omitted.
  • the above-mentioned pulse waveform generator 37 issues to the output controller 32 a pulse signal of lowered level current waveform.
  • the lowered level current pulse signal is such that, only with regard to those pulses in which the droplet detachment is detected, at least for a lowering time period t M counted from the point of time of droplet's detachment to the completion of transfer of the droplet into the weld pool, and that the pulse period is extended the lowering by an extension period t E , that is for the total time period t M +t E , where the extension period t E is set by a period extension setting circuit 38, the current is reduced to a lowered level current I r , set by the lowered current setting circuit 35, and the current I r is no higher than the peak current I p .
  • the output current waveform becomes such that it has a level I p in the first half part of the pulse period and becomes a lower value I r in the time period t M after the droplet detachment detection.
  • the arc force acting on the droplet after detachment is weakened, thereby enabling to prevent the spatter spray.
  • the lowering period t M is set by the lowering period setting circuit 34, and the extension period t E is set by the period extension setting circuit 38. If the output power of the welding is excessively reduced as a result of lowering of the current from I p to I r for the time period T M , the output voltage adversely fluctuates, thereby inducing undesirable trouble such that the welding tip does not melt; and in worst case the arc will be extinguished.
  • FIG. 13 is a drawing showing an example of a welding current waveform obtained in the present example 9.
  • FIG. 14 is a drawing showing an example of an output adjusting circuit in a tenth example of the present invention.
  • the whole or general configuration is similar to those first to sixth examples and has the same function, those aforementioned explanations and notations can be applied also in this example. Therefore redundant overlapped description is avoided here.
  • the lowering period setting circuit 34 which issues one of input signals inputted into the pulse waveform generator 37 of the above-mentioned example 9, is provided in place of the lowering period adjusting circuit 36 of the eighth example.
  • the same numerals are given and overlapped explanation thereon is omitted.
  • the action of the circuit is explained below. Hereupon, overlapped explanations on the actions of those common parts with those of the above-mentioned examples 8 and 9 are omitted.
  • a feedback signal of the welding voltage from the voltage detector 13 and the setting signal of the lowering period setting circuit 34 are inputted.
  • the lowering period t M set by the above-mentioned lowering period setting circuit 34 is issued without any adjustment from the above-mentioned lowering period control circuit 36.
  • the above-mentioned welding initial time period is set to be around 1 second.
  • the above-mentioned pulse waveform generator 37 issues to the output controller 32 the below-mentioned pulse signal of lowered level current and extension period waveform.
  • the lowered level current pulse signal is such that, only with regard to those pulses in which the droplet detachment is detected, at least for a lowering time period t M counted from the point of time of droplet's detachment to the completion of transfer of the droplet into the weld pool, added with the lowering adjustment period ⁇ t M , that is for the total, time period t M + ⁇ t M , the current is reduced to a lowered level current Ir set by the lowered time setting circuit 35, and the current Ir is no higher than the peak current Ip.
  • the lowering adjustment period ⁇ t M is set by the lowering period adjusting circuit 36.
  • the extension period t E set by the period extension setting circuit 38 can be derived from the equation (1) by using the lowering period t M set by the lowering period setting circuit 34.
  • FIG. 15 is a drawing showing an example of the output adjusting circuit in the eleventh example of the present invention.
  • the period extension setting circuit 38 which issues one of input signals inputted into the pulse waveform generator 37 of the above-mentioned tenth example, is replaced by a period extension adjusting circuit 39.
  • the setting signal of the period extension setting circuit 38 and the output signal of the voltage detector 13 are inputted into the period extension adjusting circuit 39.
  • the action of this circuit is explained below. Hereupon, explanation on the action of those parts common with that of the above-mentioned tenth example are omitted.
  • a feedback signal of the welding voltage from the voltage detector 13 and the setting signal of the period extension setting circuit 38 are inputted.
  • the extension period t E set by the above-mentioned period extension setting circuit 38 is issued without including any compensation through the above-mentioned period extension adjusting circuit 39.
  • the above-mentioned welding initial time period is normally set to be around 1 second.
  • the above-mentioned pulse waveform generator 37 issues to the output controller 32 a pulse signal of lowered level current waveform.
  • the lowered level current pulse signal is such that, only with regard to those pulses in which the droplet detachment is detected, at least for a lowering time period t M counted from the point of time of droplet's detachment to the completion of transfer of the droplet into the weld pool, added with the lowering adjustment period ⁇ t M , that is for the total time period t M + ⁇ t M , the current is reduced to a lowered level current I r set by the lowered current setting circuit 35; and the current I r is set by the lowered current setting circuit 35, and the current I r is no higher than the peak current I p .
  • the output current waveform becomes such that it has a level I p in the first half part of the pulse period and becomes a lower value of I r in the time period t M + ⁇ t M after the droplet detachment detection.
  • the arc force acting on the droplet after detachment is weakened to be able to prevent the spatter spray.
  • This lowering period t M +lowering adjusted period ⁇ t M is set by the lowering period adjusting circuit 36.
  • the extension period t E +extension adjusted period ⁇ t E can be set by the period extension adjusting circuit 39.
  • a relation between the extension adjusted period ⁇ t E and the lowering adjusted period ⁇ t M can be obtained as shown in the following equation (2):
  • FIG. 16 is a drawing showing one example of the welding current waveform obtained by the present example.

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  • Arc Welding Control (AREA)
US08/566,546 1994-12-05 1995-12-04 Apparatus for controlling consumable electrode type pulsed arc welding power source Expired - Lifetime US5834732A (en)

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US6534746B1 (en) * 1999-07-12 2003-03-18 Hetachi Construction Machinery Co., Ltd. Narrow gap welding method and welding apparatus
WO2003037560A1 (en) * 2001-10-30 2003-05-08 Tri Tool Inc. Welding current control system and method
US20040262280A1 (en) * 1998-12-24 2004-12-30 Toshisada Yasumura Arc welding method
EP1745880A2 (de) * 2005-04-14 2007-01-24 Matsushita Electric Industrial Co., Ltd. Lichtbogenschweissmaschine mit abschmelzelektrode
US20070175876A1 (en) * 2003-11-07 2007-08-02 Per Aberg Method, apparatus and software for gas metal arc welding with a continuously fed electrode
US20080237196A1 (en) * 2007-03-29 2008-10-02 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel Ltd.) Consumable electrode type gas shielded arc welding control apparatus and welding control method
US20090026186A1 (en) * 2007-07-23 2009-01-29 Daihen Corporation Pulse arc welding method
US20090242533A1 (en) * 2008-03-28 2009-10-01 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Welding control apparatus and method
US20090302014A1 (en) * 2005-09-12 2009-12-10 Esab Ab Control method for mig/mag-welding and welding equipment applying this method
US20100065540A1 (en) * 2008-03-31 2010-03-18 Hideki Ihara Welding device and setter of the same
US20110248012A1 (en) * 2009-04-08 2011-10-13 Junji Fujiwara Arc welding method and arc welding apparatus
CN102699486A (zh) * 2012-03-02 2012-10-03 深圳麦格米特电气股份有限公司 一种电弧焊焊接电源输出特性控制方法
US20140131320A1 (en) * 2012-11-09 2014-05-15 Lincoln Global, Inc. System and method to detect droplet detachment
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JP3132409B2 (ja) * 1997-03-19 2001-02-05 松下電器産業株式会社 消耗電極式パルスアーク溶接機の制御装置
DE19808383A1 (de) * 1998-02-27 1999-09-02 Volkswagen Ag Verfahren zum Metall-Schutzgas-Lichtbogen-Schweißen (MIG/MAG-Schweißen) von zwei oder mehreren Fügepartnern
US20070215585A1 (en) * 2006-03-15 2007-09-20 Lincoln Global, Inc. High current AC welder
JP5214859B2 (ja) * 2005-11-07 2013-06-19 株式会社ダイヘン 消耗電極アーク溶接電源の出力制御方法
CN1978114B (zh) * 2005-11-30 2011-03-16 陈大可 弧焊电源的电弧功率控制方法及装置
JP5350641B2 (ja) * 2007-07-23 2013-11-27 株式会社ダイヘン パルスアーク溶接方法
US8431864B2 (en) 2009-03-03 2013-04-30 Illinois Tool Works, Inc. Short circuit detection systems and methods
CN111390346B (zh) * 2020-03-11 2022-04-15 南京力骏新能源储能研究院有限公司 锂电焊机工作电流调整方法

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US20040262280A1 (en) * 1998-12-24 2004-12-30 Toshisada Yasumura Arc welding method
US6906284B2 (en) * 1998-12-24 2005-06-14 You-Chul Kim Arc welding method
US6534746B1 (en) * 1999-07-12 2003-03-18 Hetachi Construction Machinery Co., Ltd. Narrow gap welding method and welding apparatus
WO2003037560A1 (en) * 2001-10-30 2003-05-08 Tri Tool Inc. Welding current control system and method
US6794608B2 (en) * 2001-10-30 2004-09-21 Tri Tool Inc. Welding current control system and method
US20070175876A1 (en) * 2003-11-07 2007-08-02 Per Aberg Method, apparatus and software for gas metal arc welding with a continuously fed electrode
US8809737B2 (en) * 2003-11-07 2014-08-19 Esab Ab Method, apparatus and software for gas metal arc welding with a continuously fed electrode
EP1745880A4 (de) * 2005-04-14 2009-04-29 Panasonic Corp Lichtbogenschweissmaschine mit abschmelzelektrode
EP1745880A2 (de) * 2005-04-14 2007-01-24 Matsushita Electric Industrial Co., Ltd. Lichtbogenschweissmaschine mit abschmelzelektrode
US20080264916A1 (en) * 2005-04-14 2008-10-30 Motoyasu Nagano Consumable Electrode Type Arc Welding Machine
US20090302014A1 (en) * 2005-09-12 2009-12-10 Esab Ab Control method for mig/mag-welding and welding equipment applying this method
US11534848B2 (en) 2005-09-12 2022-12-27 Esab Ab Control method for MIG/MAG-welding and welding equipment applying this method
US10363626B2 (en) * 2005-09-12 2019-07-30 Esab Ab Control method for MIG/MAG-welding and welding equipment applying this method
US20080237196A1 (en) * 2007-03-29 2008-10-02 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel Ltd.) Consumable electrode type gas shielded arc welding control apparatus and welding control method
US20090026186A1 (en) * 2007-07-23 2009-01-29 Daihen Corporation Pulse arc welding method
US9061365B2 (en) * 2007-07-23 2015-06-23 Daihen Corporation Pulse arc welding method
US8153933B2 (en) 2008-03-28 2012-04-10 Kobe Steel, Ltd. Welding control apparatus and method
US20090242533A1 (en) * 2008-03-28 2009-10-01 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Welding control apparatus and method
US8309886B2 (en) * 2008-03-31 2012-11-13 Panasonic Corporation Welding device and setter of the same
US20100065540A1 (en) * 2008-03-31 2010-03-18 Hideki Ihara Welding device and setter of the same
US20110248012A1 (en) * 2009-04-08 2011-10-13 Junji Fujiwara Arc welding method and arc welding apparatus
US10500667B2 (en) * 2009-04-08 2019-12-10 Panasonic Intellectual Property Management Co., Ltd. Arc welding method and arc welding apparatus for adjusting a welding current waveform responsive to a setting voltage adjustment
CN102699486A (zh) * 2012-03-02 2012-10-03 深圳麦格米特电气股份有限公司 一种电弧焊焊接电源输出特性控制方法
US20140131320A1 (en) * 2012-11-09 2014-05-15 Lincoln Global, Inc. System and method to detect droplet detachment
US9616514B2 (en) * 2012-11-09 2017-04-11 Lincoln Global, Inc. System and method to detect droplet detachment
US20220266378A1 (en) * 2019-10-25 2022-08-25 Mitsubishi Electric Corporation Additive manufacturing apparatus
US11654510B2 (en) * 2019-10-25 2023-05-23 Mitsubishi Electric Corporation Additive manufacturing apparatus

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DE69519150T2 (de) 2001-05-10
EP0715921B1 (de) 2000-10-18
EP0715921A3 (de) 1996-07-31
EP0715921A2 (de) 1996-06-12
CN1043968C (zh) 1999-07-07
CN1129627A (zh) 1996-08-28
DE69519150D1 (de) 2000-11-23

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